Brake system

ABSTRACT

A brake system for a vehicle such as a bicycle is disclosed. The brake system may comprise an improved master cylinder assembly configured for adjustment (such as adjustment of the stroke length, stroke start, etc.). The brake system may comprise a caliper assembly with an improved arrangement of flow paths configured to facilitate maintenance (such as to remove/bleed air and/or fluid from the body of the caliper assembly, inspection, etc.); the caliper assembly may also be configured for use with a tool (e.g. configured to fit in body to remove/bleed air and/or fluid from flow paths during maintenance). The master cylinder assembly may be configured (e.g. manufactured/produced, assembled, etc.) so that a setting and/or adjustment of the brake stroke and/or lever action/actuation can be provided by any one independent mechanism or one separate adjustment mechanism (e.g. without any other adjustment mechanism) or by a combination of adjustment mechanisms (e.g. in a combination with one or more adjustment mechanism); operation of a mechanism for setting and/or adjusting the brake stroke (e.g. travel of piston) may comprise engagement of a pushrod; the mechanism may comprise a feature configured to engage the pushrod (e.g. by direct action on the pushrod or a feature of the pushrod or by indirect action through a link, adjuster, etc. configured to engage the pushrod). The master cylinder assembly may be configured to be set and/or adjusted/tuned within the indicated range to provide an intended performance and/or “feel” for the operator at the brake lever (e.g. at an adjuster, link, etc.).

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a non-provisional application of U.S.Provisional Patent Application No. 62/694,902 titled “BRAKE SYSTEM”filed Jul. 6, 2018.

The present application claims priority to and incorporates by referencein full the following patent application: U.S. Provisional PatentApplication No. 62/694,902 titled “BRAKE SYSTEM” filed Jul. 6, 2018.

FIELD

The present invention relates to a brake system for a vehicle such as abicycle.

The present invention relates to brake system comprising an improvedmaster cylinder assembly.

The present invention relates to a brake system comprising an improvedcaliper assembly.

The present invention relates to a brake system for a vehicle such as abicycle comprising an improved master cylinder assembly and/or animproved caliper assembly.

BACKGROUND

It is known to provide a brake system for a vehicle such as a bicycle.It is also known to provide a brake system comprising a master cylinderassembly and a caliper assembly.

A master cylinder assembly for a known brake system may comprise a setof brake levers to actuate the operation of the braking function for thebicycle (e.g. one for each of the front wheel and the rear wheel). Insuch known brake systems, each brake lever may be provided at agenerally fixed position notwithstanding the advantages of providing foradjustment of the position and/or of the sensitivity/lag of the brakingfunction in operation and/or of adjustment of possible variation inposition/sensitivity of each brake lever.

A caliper assembly for a known brake system may comprise a set ofpistons in operation under control (e.g. by hydraulic/brake fluid) ofthe master cylinder assembly (e.g. at each brake lever); the caliperassembly of the brake system (including each set of pistons) may fromtime to time require maintenance (e.g. removal/bleed of air that may beentrapped, drain old fluid, refill of new fluid, etc.) and/orinspection; for certain known brake systems, such maintenance mayrequire actions that are relatively time-consuming/inefficient.

It would be advantageous to provide a brake system for a vehicle such asa bicycle comprising an improved master cylinder assembly and/or animproved caliper assembly.

It would be advantageous to provide a brake system for a vehicle such asa bicycle comprising an improved master cylinder assembly configured toallow for setting of the initial position of the piston for performanceand preference/comfort of the operator.

It would be advantageous to provide a brake system for a vehicle such asa bicycle comprising an improved master cylinder assembly havingmultiple adjustments for performance and preference/comfort of theoperator.

It would be advantageous to provide an improved caliper assembly tofacilitate convenient maintenance (e.g. removal/bleed of air that may beentrapped, drain/refill/replace fluid, etc.).

It would be advantageous to provide an improved caliper assemblyprovided with a tool to facilitate convenient maintenance (e.g.removal/bleed of air that may be entrapped, drain/refill/replace fluid,etc.), inspection, etc.

SUMMARY

The present invention relates to brake system comprising an improvedmaster cylinder assembly.

The present invention relates to a brake system comprising an improvedcaliper assembly.

The present invention relates to a brake system for a vehicle such as abicycle comprising an improved master cylinder assembly and/or animproved caliper assembly.

The present invention relates to a brake system configured to beoperable by an actuator comprising a caliper assembly and a mastercylinder assembly. The master cylinder assembly may comprise a body anda piston configured to move from an initial stroke position along a fullstroke within the body to actuate braking action at the caliper assemblyand a pushrod configured to engage the piston and a link actuated by theactuator and configured to engage the pushrod into engagement with thepiston; the initial stroke position of the piston may be configured tobe set by a feature acting at the link engaged at the pushrod andconfigured to determine a distance of movement by the actuator beforebraking action is actuated at the caliper assembly. The caliper assemblymay comprise a body configured to provide a series of flow paths tofacilitate maintenance by facilitating flow of fluid within and from thebody; the caliper assembly further may comprise plugs to direct fluidwithin and from the body. The caliper assembly may be configured for useof a tool to facilitate maintenance.

The present invention relates to a brake system comprising a mastercylinder assembly. The master cylinder assembly may comprise a body anda piston configured to move from an initial stroke position along astroke within the body and a pushrod configured to engage the piston anda link coupled within the body and configured to engage the pushrod. Theinitial stroke position of the piston may be configured to be set by afeature acting at the link engaged at the pushrod. The feature maycomprise a threaded end on the pushrod and a bushing on the link; theinitial stroke position of the piston may be set by relative position ofthe threaded end of the pushrod to the bushing on the link. The initialstroke position of the piston may be configured to be adjusted by thefeature. The initial stroke position of the piston may be configured tobe set by contact between the feature and the pushrod; the feature maybe on the link; and the initial stroke position of the piston may beconfigured to be set by the feature on the link as a stop for thepushrod. The initial stroke position of the piston may be configured tobe adjusted by contact between the feature and the pushrod. The featuremay be on the link; the feature on the link may be configured to engagethe pushrod as a stop; and the initial stroke position of the piston maybe configured to be adjusted by the feature on the link as a stop forthe pushrod. The system may comprise an adjuster; the feature may be onthe pushrod; and the adjuster may be configured to be adjusted to engagethe feature on the pushrod to set the initial stroke position of thepiston. The adjuster may comprise an adjuster screw; the feature on thepushrod may comprise a flange. The system may comprise an adjuster; thefeature may be on the pushrod; contact by the adjuster may comprisecontact with the feature on the pushrod. The adjuster may be configuredto adjust the initial stroke position of the piston by engagement withthe pushrod. The initial stroke position of the piston may determine alength of stroke of the piston before braking action at a caliperassembly. The stroke of the piston may comprise a full stroke set bycontact between the pushrod and the body.

The present invention relates to a brake system configured to beactuated by an actuator comprising a master cylinder assembly. Themaster cylinder assembly may comprise a body and a piston configured tomove from an initial stroke position along a stroke within the body anda link actuated by the actuator and configured to actuate the piston anda mechanism configured to adjust an initial position of the actuator;the mechanism may comprise an adjuster configured to contact the link.The link may comprise a pivot link coupled within the body. The adjustermay comprise a slide having a threaded portion and an unthreadedportion. The adjuster may comprise a detent mechanism. The actuator maycomprise a brake lever; the mechanism may be configured to adjust theinitial position of the brake lever.

The present invention relates to a brake system comprising a mastercylinder assembly comprising a lever and a piston and configured tofacilitate adjustment of the stroke (e.g. start/cut-off of the brakingaction/stroke of the lever and/or piston actuated by the lever) by atleast one of adjustment of the position of the pushrod acting on thepiston and/or adjustment of an adjuster screw acting upon the pushrodacting on the piston and/or adjustment of a slide/bolt configured toadjust the default position the lever.

The present invention relates to a brake system comprising a caliperassembly comprising a body and a piston assembly and configured tofacilitate maintenance including the removal/bleed of undesirablematter/material such as air from the body.

The present invention relates to a brake system comprising a caliperassembly comprising a body and a piston assembly and configured withflow paths to facilitate maintenance including the removal/bleed ofundesirable matter/material such as air from the body and/orinspection/lubrication of the piston assembly.

The present invention relates to a brake system comprising a caliperassembly comprising a body and a piston assembly and configured for usewith a tool to facilitate maintenance including the removal/bleed ofundesirable matter/material such as air from the body and/orinspection/lubrication of the piston assembly; the tool may beconfigured to fit within the body of the caliper assembly and maycomprise features such as a set of ridges and a flat section configuredto engage with the body and piston assembly to facilitate maintenance.

The present invention relates to a brake system configured to beoperable by an actuator; the brake system may comprise a caliperassembly and a master cylinder assembly; the master cylinder assemblymay comprise a body and a piston configured to move from an initialstroke position along a full stroke within the body to actuate brakingaction at the caliper assembly and a pushrod configured to engage thepiston and a link actuated by the actuator and configured to engage thepushrod into engagement with the piston; the initial stroke position ofthe piston may be configured to be set by a feature engaged at thepushrod and configured to determine a distance of movement by theactuator before braking action is actuated by the piston at a caliperassembly. The initial stroke position of the piston may be configured tobe set by contact between the feature and the pushrod. The initialstroke position of the piston may be configured to be adjusted bycontact between the feature and the pushrod. The caliper assembly maycomprise a body configured to provide a series of flow paths tofacilitate maintenance by facilitating flow of fluid within and from thebody. The caliper assembly may be configured for use of a tool tofacilitate maintenance. The caliper assembly further may comprise plugsto direct of fluid within and from the body.

The present invention relates to a brake system comprising a mastercylinder assembly comprising a body and a piston configured to move froman initial stroke position along a stroke within the body and a pushrodconfigured to engage the piston and a link coupled within the body andconfigured to engage the pushrod; the initial stroke position of thepiston may be set by a feature engaged at the pushrod. The initialstroke position of the piston may be configured to be adjusted by thefeature. The initial stroke position of the piston may be configured tobe set by contact between the feature and the pushrod. The initialstroke position of the piston may be configured to be adjusted bycontact between the feature and the pushrod. The feature may be on thelink; and the initial stroke position of the piston may be configured tobe set by the feature on the link as a stop for the pushrod. The featuremay be on the link; the feature on the link may be configured to engagethe pushrod as a stop; and the initial stroke position of the piston maybe configured to be set by the feature on the link as a stop for thepushrod. The feature may be on the link; the feature on the link may beconfigured to engage the pushrod as a stop; and the initial strokeposition of the piston may be configured to be adjusted by the featureon the link as a stop for the pushrod. The system may comprise anadjuster; the feature may be on the pushrod; and the adjuster may beconfigured to be set to engage the feature on the pushrod to set theinitial stroke position of the piston. The system may comprise anadjuster; the feature may be on the pushrod; and the adjuster may beconfigured to be adjusted to engage the feature on the pushrod to setthe initial stroke position of the piston. The adjuster may comprise anadjuster screw. The feature on the pushrod may comprise a flange. Theadjuster may be configured to contact the pushrod. The feature may be onthe pushrod; wherein contact by the adjuster may comprise contact withthe feature on the pushrod. The adjuster may be configured to set theinitial stroke position of the piston by engagement with the pushrod.The adjuster may be configured to adjust the initial stroke position ofthe piston by engagement with the pushrod. The initial stroke positionof the piston set by a feature engaged at the pushrod may be configuredto determine a length of stroke of the piston before braking action at acaliper assembly. The feature may comprise a threaded end on the pushrodand a bushing on the link; wherein the initial stroke position of thepiston may be set by relative position of the threaded end of thepushrod to the bushing on the link. The stroke of the piston maycomprise a cutoff stroke set by contact between the pushrod and thepiston. The stroke of the piston may comprise a full stroke set bycontact between the pushrod and the body.

The present invention relates to a brake system configured to beactuated by an actuator and comprising a master cylinder assembly; themaster cylinder system may comprise a body and a piston configured tomove from an initial stroke position along a stroke within the body; anda pushrod configured to engage the piston and a link actuated by theactuator and configured to engage the pushrod into engagement with thepiston and a mechanism configured to set an initial position of thelink; the initial stroke position of the piston may be configured to beset by a feature engaged at the pushrod. The mechanism may be configuredto adjust the initial position of the link. The mechanism may comprisean adjuster configured to contact the link. The mechanism may comprise aslide adjuster. The link may comprise a pivot link coupled within thebody. The mechanism may comprise a slide having a threaded portion andan unthreaded portion. The mechanism may comprise a detent mechanism.The mechanism may be configured to set the initial position of the linkindependently of the initial stroke position of the piston set by thefeature engaged at the pushrod. The mechanism may comprise a torsionspring. The actuator may comprise a brake lever. The mechanism may beconfigured to adjust the dead stroke of the brake lever. The mechanismmay be configured to adjust reach for the brake lever. The initialstroke position of the piston may be configured to be adjusted by thefeature engaged at the pushrod.

FIGURES

FIG. 1 is a schematic perspective view of a bicycle with a brake systemaccording to an exemplary embodiment.

FIG. 2 is a schematic perspective view of a master cylinder assembly anda caliper assembly for a brake system for a vehicle such as a bicycleaccording to an exemplary embodiment.

FIG. 3A is a schematic perspective view of a master cylinder assemblyfor a brake system according to an exemplary embodiment.

FIG. 3B is a schematic exploded perspective view of a master cylinderassembly for a brake system according to an exemplary embodiment.

FIG. 4 is a schematic side elevation view of a master cylinder assemblyfor a brake system according to an exemplary embodiment.

FIG. 5 is a schematic top plan view of a master cylinder assembly for abrake system according to an exemplary embodiment.

FIGS. 6A to 6C are schematic side elevation cross-section views of amaster cylinder assembly for a brake system according to an exemplaryembodiment.

FIGS. 7A and 7B are schematic partial side elevation cross-section viewsof a master cylinder assembly for a brake system according to anexemplary embodiment.

FIG. 8 is a schematic perspective view of a tool for adjustment of amaster cylinder assembly of a brake system according to an exemplaryembodiment.

FIGS. 9A and 9B are schematic partial side elevation cross-section viewsof a master cylinder assembly for a brake system according to anexemplary embodiment.

FIG. 10 is a schematic perspective view of a tool for adjustment of amaster cylinder assembly of a brake system according to an exemplaryembodiment.

FIGS. 11A and 11C are schematic side elevation cross-section views of amaster cylinder assembly for a brake system according to an exemplaryembodiment.

FIGS. 11B and 11D are schematic partial side elevation cross-sectionviews of a master cylinder assembly for a brake system according to anexemplary embodiment.

FIGS. 12A and 12B are schematic side elevation cross-section views of amaster cylinder assembly for a brake system according to an exemplaryembodiment.

FIG. 13 is a schematic partial side elevation cross-section views of amaster cylinder assembly for a brake system according to an exemplaryembodiment.

FIG. 14A is a schematic side elevation view of a caliper assembly for abrake system according to an exemplary embodiment.

FIG. 14B is a schematic perspective view of a caliper assembly for abrake system according to an exemplary embodiment.

FIG. 14C is a schematic exploded perspective view of a caliper assemblyfor a brake system according to an exemplary embodiment.

FIGS. 15A and 15B are schematic perspective views of a tool for acaliper assembly of a brake system according to an exemplary embodiment.

FIG. 16A is a schematic perspective view of a caliper assembly and toolfor a brake system according to an exemplary embodiment.

FIG. 16B is a schematic front elevation view of a caliper assembly andtool for a brake system and tool according to an exemplary embodiment.

FIGS. 17A and 18A and 19A are schematic plan views of a caliper assemblywith tool for a brake system according to an exemplary embodiment.

FIGS. 17B and 18B and 19B are schematic plan cross-section views of acaliper assembly with tool for a brake system according to an exemplaryembodiment.

FIG. 20A is a schematic front elevation view of a caliper assembly andtool for a brake system according to an exemplary embodiment.

FIGS. 20B and 20C are a schematic perspective views of a caliperassembly and tool for a brake system according to an exemplaryembodiment.

FIGS. 21A to 21C are schematic plan cross-section views of a caliperassembly with tool for a brake system according to an exemplaryembodiment.

TABLES

TABLE A is a reference symbol list for the bicycle with brake systemaccording to an exemplary embodiment.

TABLE B is a reference symbol list for the master cylinder assembly ofthe brake system according to an exemplary embodiment.

TABLE C is a reference symbol list for the caliper assembly of the brakesystem according to an exemplary embodiment.

DESCRIPTION

Referring to FIG. 1, a bicycle B (such as a mountain bike) is shownschematically according to an exemplary embodiment providing anarrangement of parts/components including a frame FR with a steeringtube T and a seat post SP (with seat S) and a set of wheels comprisingfront wheel FW with a front fork assembly F and rear wheel RW coupled tothe frame FR and through a rear shock absorber SH (of a suspensionsystem) and a set of pedals P; the bicycle provides handlebar H (coupledby stem ST to front wheel FW through front fork assembly F and throughsteering tube T) with a grip G and controls for a brake system BRcoupled to a brake disc D (e.g. rotor at/on each of front wheel FW andrear wheel RW).

According to an exemplary embodiment shown schematically in FIG. 2,components of a brake system/assembly for a bicycle may comprise amaster cylinder assembly 100 configured to be mounted on the handlebarand a caliper assembly 300 configured to be mounted on a fork structure(e.g. fork for wheel) or frame to engage the brake rotor/disc andcoupled by a tube 380 (e.g. providing a passage for flow ofhydraulic/brake fluid to actuate the braking function under operatorcontrol of the master cylinder assembly). See also FIGS. 3A-3B to11A-11D (exemplary embodiment of master cylinder assembly) and FIGS.14A-14C to 21A-21C (exemplary embodiment of caliper assembly).

Brake System—Master Cylinder Assembly

As shown schematically according to an exemplary embodiment in FIGS. 1and 2, the brake system BR may comprise a master cylinder assembly 100.

As shown schematically in FIGS. 3A-3B, the master cylinder assembly 100may comprise a body 105 with a cover shown as plate 210 (secured byscrews 215) for a top chamber shown as reservoir configured to holdbladder 205 (e.g. separating air and hydraulic/brake fluid) (and with aset of plugs shown bleed plugs 230) and configured to be secured to thehandlebar of a bicycle with a clamp assembly shown as comprising a clampsection 220 and screws 225.

As shown schematically in FIGS. 3A-3B, body 105 comprises an internalchamber or bore (for hydraulic/brake fluid in communication through ahole 105 b with the top chamber/reservoir containing hydraulic/brakefluid and bladder to contain air) configured to contain a pistonsystem/arrangement comprising a piston 110 with a spring 130 and abushing 115 and a primary cup 120 and a secondary cup 125 engaged with apushrod 135 secured on a fitting comprising a nut 140 contained in abushing 145 and retained with a set screw 240. See aloo FIGS. 6A-6C.

As shown schematically according to an exemplary embodiment in FIGS.3A-3B, 4-5 and 6A-6C, the master cylinder assembly 100 may comprise alever assembly comprising a lever 155 coupled to body 105 and configuredto actuate a link 150 engaged with the piston assembly; the leverassembly is configured with an adjustment system comprising a peg/slide160 (e.g. with flat 160 a configured to be fit in flat 155 b of thelever 155) and an adjuster mechanism providing a ring/knob 170configured in a detent arrangement with a plate/washer 175 (with flat160 a of the slide 160 configured to be fit in flat 175 b of theplate/washer 175) with ball 180 and spring 185 (e.g. providing a set ofadjustment positions 175 a for rotation of knob 170); link 150 ispivotally coupled to body 105 on a shaft/axle shown as pivot nut 190secured with a set of pins shown as bolts 202 on bearings 195 (e.g.press-fit into the body 105) with a spring arrangement shown ascomprising torsion spring 165 (e.g. biasing spring) and retained with anadjuster screw 235. See also FIGS. 11A-11D.

As shown schematically according to an exemplary embodiment in FIGS.6A-6C, the master cylinder assembly is operated (e.g. to provide brakingfunction) by actuation of the lever 155 operating through slide 160(against spring 165) on link 150 on bushing 145 on nut 140 on pushrod135 to advance piston 110 against spring 130 into the bore in body 105(see FIGS. 6B and 6C) and to transmit hydraulic/brake fluid to a caliperassembly to effectuate the braking function on the wheel (see FIGS. 1, 2and 14A). See also FIGS. 12A-12B and 13 (master cylinder assembly 400with piston arrangement including piston 110 and with pushrod 435 withlink 450).

As shown schematically according to an exemplary embodiment in FIGS.6A-6C, the master cylinder assembly is configured for setting/adjustmentof the brake stroke (e.g. start, travel, etc.); as indicatedschematically in FIG. 6A, the start of the stroke of the brake may beset by the position at which a feature engages the pushrod 135 (e.g afeature such as on link 150 and/or a feature such as an adjuster/screw235 configured to engage the pushrod 135 (e.g. on a feature such asflange 135 a)); the feature on and/or connected to the link may beformed/shaped and configured so that setting/adjustment of the brakestroke and/or lever action/actuation may be provided by directengagement; as indicated schematically, the feature may be configured toengage the pushrod (e.g. on a surface of the pushrod and/or a featuresuch as the flange of the pushrod, etc. and with/without the adjustmentscrew/adjuster). As shown schematically in FIG. 6C, the full strokelimit may be set by the position at which the flange 135 a of thepushrod 135 engages the end surface 105 a of the body 105 (e.g. as amechanical stop). As indicated schematically in FIG. 3B, set screw 240is provided to retain the adjustment setting of pushrod 135 (e.g. inposition as adjusted).

As indicated schematically according to an exemplary embodiment in FIGS.3B, 7A-7B, 9A-9B and 11A-11D, the master cylinder assembly is configuredfor setting/adjustment of the lever action/actuation (e.g. sensitivity,feel, travel before engagement, dead zone/lag, etc.). According to anexemplary embodiment, the lever action/actuation for master cylinderassembly can be adjusted so that an operator can balance (e.g. accordingto purpose, preference, etc.) such considerations as producing intendedsimilarity or variation in sensitivity/feel of each brake lever (e.g.control for braking at front/rear wheel), dead zone/travel of the brakelever before the operation of the braking function is initiated, etc.

As indicated schematically according to an exemplary embodiment in FIGS.7A-7B and 8, the master cylinder assembly is configured forsetting/adjustment of the lever action/actuation by adjustment of thecutoff stroke (C) of the piston 110 with threaded adjustment of theposition (P) of the pushrod 135 at end/recess 135 b (e.g. adjustedposition in threaded bushing 140 by rotation/engagement with end 245 aof tool 245); with pushrod 135 adjusted to position P1 the piston 110will have a cutoff stroke C1 (e.g. representative of a factory defaultsetting with a relatively small dead zone/lag before engagement) (seeFIG. 7A); with pushrod 135 adjusted to position P2 the piston 110 willhave a reduced cutoff stroke C2 (e.g. virtually no lag beforeengagement) (see FIG. 7B).

As indicated schematically according to an exemplary embodiment in FIGS.9A-9B and 10, the master cylinder assembly is configured for adjustmentof the lever action/actuation by adjustment of the cutoff stroke (C) ofthe piston 110 with adjustment of the pushrod 135 by threaded adjustmentof the relative position (D) of adjuster screw 235 (e.g. adjusted byengagement with end of tool 250 to a relative position indicated asbetween head 235 a of the adjuster screw 235 and surface 150 b of thelink 150); with pushrod 135 adjusted at flange 135 a by adjuster screwat relative position D1 the piston 110 will have a reduced cutoff strokeC2 (see FIG. 9A indicating an adjustment limit/stop with head 235 a ofadjuster screw engaged in contact at surface 150 b of link 150); withpushrod 135 adjusted at flange 135 a by adjuster screw at relativeposition D2 the piston 110 will have a lengthened cutoff stroke C3 (e.g.greater lag before engagement) (see FIG. 9B).

As indicated schematically according to an exemplary embodiment in FIGS.11A-11B and 11C-11D, the master cylinder assembly is configured foradjustment of the lever action/actuation (e.g. default position of lever155) by threaded adjustment of the position (R) of slide 160 by adjusterknob 170 (e.g. adjusted by the ball/spring detent mechanism for therotary adjuster knob) for engagement with link 150 and actuation ofpushrod 135 and piston 110. Referring to FIGS. 11A and 11B, with slide160 adjusted to a fully retracted position R1 by adjuster knob 170 (seeFIG. 11B indicating an adjustment/limit stop with shoulder 155 a oflever 155 engaged in contact at surface 150 a of link 150) the defaultposition of lever 155 is in effect fully extended relative to the body105 (see FIGS. 11A-11B) (e.g. shorter distance for operator hand/fingersbefore engagement at the lever). Referring to FIGS. 11C and 11D, withslide 160 adjusted to a fully extended position R2 by adjuster knob 170(see FIG. 11D indicating an adjustment limit/stop by unthreaded flangesection 160 b of slide 160) the default position of lever 155 is ineffect fully retracted relative to the body 105 (see FIGS. 11C-11D)(e.g. greater distance for operator hand/fingers before engagement atthe lever) (see FIG. 9B). See also FIGS. 9A-9B (showing slide 160 in anintermediate position of adjustment between position R1 and positionR2).

As indicated schematically in FIGS. 3B and 6A-6C, 7A-7B, 9A-9B and11A-11D, according to an exemplary embodiment the master cylinderassembly may be configured (e.g. manufactured/produced, assembled, etc.)so that adjustment of the brake stroke and/or lever action/actuation canbe provided by any one independent or separate adjustment mechanism(e.g. without any other adjustment mechanism) or by a combination ofadjustment mechanisms (e.g. in a combination with one or more adjustmentmechanism) or by variations in the configuration one (or more) of theadjustment mechanisms; for example, according to an exemplaryembodiment, the link 150 (e.g. by a feature such as contact point on thelink shown as link 150) and/or the pushrod 135 (e.g. by a feature suchas contact point such as a flange or other feature on the pushrod shownas flange 135 a of pushrod 135) may be formed/shaped and configured sothat adjustment of the brake stroke and/or lever action/actuation may beprovided by direct engagement of a surface of the link and the pushrod(e.g. with/without the adjustment screw/adjuster, with/without theflange, etc,).

As shown schematically according to an exemplary embodiment in FIGS.12A-12B and 13, the master cylinder assembly 400 is configured forsetting/adjustment of the brake stroke (e.g. start, travel, etc.); asindicated schematically, the start of the stroke of the brake may be setby the position at which a feature 450 a on link 450 engages the pushrod435 (e.g a feature on or connected to link 450 such as a projection,surface, cam, stop, limit, etc.); the feature on and/or connected to thelink may be formed/shaped and configured so that setting/adjustment ofthe brake stroke and/or lever action/actuation may be provided by directengagement (e.g. as a mechanism, mechanical stop, etc. with engagementof the link/feature and the pushrod/feature); as indicatedschematically, the feature may be a surface on the link and/or a featureof the link configured to engage of a surface of the pushrod and/or afeature of the pushrod. As indicated schematically, the full strokelimit may be set by the position of a stop within body 105 of the mastercylinder assembly 400 (e.g. as a mechanical stop).

As indicated schematically according to an exemplary embodiment, themaster cylinder assembly 400 is configured for setting/adjustment of thelever action/actuation (e.g. sensitivity, feel, travel beforeengagement, dead zone/lag, etc.). According to an exemplary embodiment,the lever action/actuation for master cylinder assembly can beset/adjusted so that an operator can balance (e.g. according to purpose,preference, etc.) such considerations as producing intended similarityor variation in sensitivity/feel of each brake lever (e.g. control forbraking at front/rear wheel), dead zone/travel of the brake lever beforethe operation of the braking function is initiated, etc.

As indicated schematically in the FIGURES, according to an exemplaryembodiment the master cylinder assembly may be configured to beadjusted/tuned within the indicated range to provide an intendedperformance for the operator.

Brake System—Caliper Assembly

As shown schematically according to an exemplary embodiment in FIGS. 1and 2, the brake system BR may comprise a caliper assembly 300.

As shown schematically in FIGS. 14A-14C, the caliper assembly 300 maycomprise a body/body assembly (configured to contain hydraulic/brakefluid) comprising an outer body 305 (with a set of chambers providedwith a plug shown as bleed plug 340) and an inner body 310 (with a setof chambers each provided with a plug shown as bleed plug 340) and aseal 315; outer body 305 is configured to be mounted on thefork/structure and comprises a mounting arrangement shown as comprisingflanges 308 configured to engage features on the fork or frame structureand provides adjuster screws 345 configured to engage apertures/slots308 a in flanges 308 (e.g. for mounting/adjustment of position of thebody of the caliper assembly on the fork or frame structure).

As shown schematically in FIGS. 14A-14C, outer body 305 and inner body310 are assembled to form a recess/slot for the disc/rotor D of thewheel and secured by screws 330 to provide a network/set of flow pathsfor hydraulic/brake fluid and to contain a piston arrangement operatedby hydraulic/brake fluid for the set of chambers in the body assembly(e.g. controlled and configured to engage/release the brake rotor/discon the wheel in operation of the braking function through the brake padassembly engaged with the set of pistons); the piston arrangementcomprises a set of piston assemblies comprising a piston 325 fitted andsecured with seals shown as square seals/rings 320 for each set ofchambers in the body assembly and configured to be actuated in brakingoperation (e.g. to engage/release the brake pad against the disc/rotorfor the wheel). As shown schematically in FIG. 14C, the caliper assemblymay comprise a set of brake pads 350 engaged with the piston arrangementthrough a spring shown as pad spring 355 attached by a screw shown asbrake pad screw 335.

As shown schematically according to an exemplary embodiment in FIGS. 2,14A-14C and 16A-16B, the body of the caliper assembly 300 is coupled byfluid connection (e.g. hydraulic brake fluid circuit/flow) through acoupling/interface (e.g. conduits/connectors shown as fitting/banjo 360and connector/banjo bolt 370 with coupling/sleeve 375) at port/hose 380to the master cylinder assembly of the brake system (e.g. configured sothat lever action at the master cylinder assembly transmitted by thebrake fluid will actuate the operation of the braking function toengage/release the brake pad on the rotor/disc at the wheel). See alsoFIG. 1.

As shown schematically according to an exemplary embodiment in FIGS.15A-15B, 16A-16B and 20A-20C, a tool shown as block or bleed block 385may be provided and configured to facilitate maintenance by selectiveengagement with the piston arrangement upon installation/insertion intoa recess in the body of the caliper assembly 300.

Referring to FIGS. 15A-15B and 20B-20C, as shown schematically accordingto an exemplary embodiment, one end of tool/block 385 comprises a set oftwo ridge sections 385 b (one multiple-ridge section on each side of thesurface of the tool/block); one end of tool/block 385 comprises a ridgesection 385 c and a flat/flat surface section 385 d (one multiple-ridgesection on one side of the surface and one flat section on one side ofthe surface of the tool/block) and flanges 385 a. See also FIGS. 20B and20C.

As shown schematically according to an exemplary embodiment in FIGS.16A-16B and 20A-20C, block 385 is configured to be installed/insertedinto the recess of the body 305/310 of the caliper assembly 300 in avariety of orientations. Compare FIGS. 16A-16B, 17A-17B, 18A-18B and19A-19B (e.g. insertion of tool/block 385 in orientation with two ridgesections 385 b engaging and retaining sets of pistons 325 on both ofouter body 305 and inner body 310) and FIGS. 20A-20C and 21A-21C (e.g.insertion of tool/block 385 in orientation with flanges 385 a seated inslots 310 d of the body and one ridge section 385 c engaging andretaining one set of pistons 325 on outer body 305 and flat section 385d providing space/allowing movement of one set of pistons 325 on innerbody 310).

As indicated schematically according to an exemplary embodiment in FIGS.16A-16B, 17A-17B, 18A-18B and 19A-19B, the tool shown block 385 isconfigured to be installed/inserted in coordination with the use ofplugs shown as bleed plugs 340 to facilitate the flow/bleed of airand/or fluid within and from the body of the caliper assembly 300. (Theflow paths according to an exemplary embodiment have been indicatedschematically with an indicated example direction of flow F; inuse/operation the flow through the indicated flow paths may be providedin the indicated example direction or in areverse/opposed/counter-direction through the indicated flow paths.)

As shown schematically in FIGS. 17A-17B, with block 385installed/inserted so that ridge sections 385 b engage and retain theset of pistons 325 in inner body 310 and the set of pistons 325 in outerbody 305 and with a bleed plug removed from port 305 c of outer body 305and with bleed plug 340 inserted in port 310 c of inner body 310 a flowpath is established (as indicated schematically by flow F) in the bodyfrom the port/hose 380 through passage 360 a and passage 370 a and toand through passage 305 a and passage 305 b and port 305 c of outer body305 of caliper assembly 300 (e.g. removing/bleeding air and/or fluidfrom the outer body).

As shown schematically in FIGS. 18A-18B, with block 385installed/inserted so that ridge sections 385 b engage and retain theset of pistons 325 in inner body 310 and the set of pistons 325 in outerbody 305 and with bleed plug 340 inserted in port 305 c of outer body305 and with bleed plug removed from port 310 c of inner body 310 a flowpath is established (as indicated schematically by flow F) in the bodyfrom the port/hose 380 through passage 360 a and passage 370 a and toand through passage 310 a and passage 310 b and port 310 c of inner body310 of caliper assembly 300 (e.g. removing/bleeding air and/or fluidfrom the inner body).

As shown schematically in FIGS. 19A-19B, with block 385installed/inserted so that ridge sections 385 b engage and retain theset of pistons 325 in inner body 310 and the set of pistons 325 in outerbody 305 and with a bleed plug removed from port 305 c of outer body 305and with bleed plug removed from port 310 c of inner body 310 and withthe port/hose 380 closed a flow path is established (as indicatedschematically by flow F) within the body through port 305 c and passage305 b and passage 305 a of outer body 305 of caliper assembly 300 and toand through passage 310 a and passage 310 b and port 310 c of inner body310 of caliper assembly 300 (e.g. removing/bleeding air and/or fluidfrom the entire body of the caliper assembly).

As indicated schematically according to an exemplary embodiment, thecaliper assembly is configured to provide flow paths that facilitate theremoval/bleed of air (e.g. by providing ports, flow/bleed paths,double-bleed flow paths, etc. independent of the use of a tool/block toassist). See FIGS. 17A-17B, 18A-18B and 19A-19B. As indicatedschematically, a flow path may be established (as indicatedschematically by flow F) in the body from the port/hose 380 throughpassage 360 a and passage 370 a and to and through passage 305 a andpassage 305 b and port 305 c of outer body 305 of caliper assembly 300(e.g. removing/bleeding air and/or fluid from the outer body) withoutthe need of the took/block (see FIGS. 17A-17B); a flow path may beestablished (as indicated schematically by flow F) in the body from theport/hose 380 through passage 360 a and passage 370 a and to and throughpassage 310 a and passage 310 b and port 310 c of inner body 310 ofcaliper assembly 300 (e.g. removing/bleeding air and/or fluid from theinner body) (see FIGS. 18A-18B); with the port/hose 380 closed a flowpath is established (as indicated schematically by flow F) within thebody through port 305 c and passage 305 b and passage 305 a of outerbody 305 of caliper assembly 300 and to and through passage 310 a andpassage 310 b and port 310 c of inner body 310 of caliper assembly 300(e.g. removing/bleeding air and/or fluid from the entire body of thecaliper assembly) (see FIGS. 19A-19B).

As shown schematically in FIGS. 20A, 20C and 21A-21C, with block 385installed/inserted so that ridge section 385 c engages and retains theset of pistons 325 in outer body 305 (the set of pistons 325 in innerbody 310 is not engaged or retained by flat section 385 d) and withbleed plug 340 inserted in port 310 c of inner body 310 and with bleedplug 340 inserted in port 305 c of outer body 305 the set of pistons 325in inner body 310 are able to move by actuation to position formaintenance (e.g. lubrication, etc.). As indicated schematically in FIG.20B, with block 385 installed/inserted so that ridge section 385 cengages and retains the set of pistons 325 in inner body 310 (the set ofpistons 325 in outer body 305 is not engaged or retained by flat section385 d) and with bleed plug 340 inserted in port 310 c of inner body 310and with bleed plug 340 inserted in port 305 c of outer body 305 the setof pistons 325 in outer body 305 are able to move by actuation toposition for maintenance (e.g. lubrication, etc.).

As shown schematically in FIGS. 20B and 20C, tool/block 385 isconfigured to be installed into the recess of the body 305/310 of thecaliper assembly 300 (e.g. with flanges 385 a seated in slots 310 d ofthe body).

As indicated schematically according to an exemplary embodiment, thecaliper assembly is configured to provide flow paths that facilitate theremoval/bleed of air (e.g. by providing ports, flow/bleed paths,double-bleed flow path, etc.) with or without the use of a tool/block.

Tables—Reference Symbols

TABLE A REFERENCE SYMBOL ELEMENT, PART OR COMPONENT B BICYCLE FR FRAMEFW FRONT WHEEL RW REAR WHEEL SP SEAT POST S SEAT T STEERING TUBE ST STEMH HANDLEBAR G GRIP (HANDLEBAR) F FRONT FORK ASSEMBLY SH REAR SHOCKABSORBER FOR SUSPENSION SYSTEM BR BRAKE SYSTEM D DISC/ROTOR (BRAKE) PPEDAL

TABLE B REFERENCE SYMBOL ELEMENT, PART OR COMPONENT 100/400 MASTERCYLINDER ASSEMBLY 105 BODY with end surface 105a and port timing hole105b 110 PISTON 115 BUSHING 120 PRIMARY CUP 125 SECONDARY CUP 130 SPRING135/435 PUSHROD (with flange 135a and recess 135b) 140 NUT 145 BUSHING150/450 LINK (with shoulder 150a and end surface 150b or feature 450a)155 LEVER with shoulder 155a and flats 155b 160 SLIDE with flats 160aand flange 160b 165 TORSION SPRING 170 ADJUSTER KNOB 175 PLATE (WASHER)with flats 175a and slots 175b 180 BALL 185 SPRING 190 PIVOT NUT 195BEARING 202 BOLT 205 BLADDER 210 COVER 215 SCREW 220 CLAMP (BASE) 225SCREW (CLAMP) 230 BLEED PLUG 235 ADJUSTER SCREW with head 235a 240 SETSCREW 245 TOOL with tip 245a 250 TOOL

TABLE C REFERENCE SYMBOL ELEMENT, PART OR COMPONENT 300 CALIPER ASSEMBLY305 OUTER BODY (with passages 305a/305b and port 305c) 310 INNER BODY(with passages 310a/310b and port 310c and slot 310d) 315 SEAL 320SQUARE SEAL 325 PISTON 330 SCREW 335 PAD PIN 340 BLEED PLUG 345 ADJUSTERSCREW 350 BRAKE PAD 355 PAD SPRING 360 CONNECTOR/CONDUIT (BANJO) withpassage 360a 365 SEAL 370 CONNECTOR/CONDUIT (BANJO BOLT) with passage370a 375 SLEEVE 380 HOSE 385 TOOL/BLEED BLOCK (with flanges 385a andridge sections 385b/c and flat section 385d)

It is important to note that the present inventions (e.g. inventiveconcepts, etc.) have been described in the specification and/orillustrated in the FIGURES of the present patent document according toexemplary embodiments; the embodiments of the present inventions arepresented by way of example only and are not intended as a limitation onthe scope of the present inventions. The construction and/or arrangementof the elements of the inventive concepts embodied in the presentinventions as described in the specification and/or illustrated in theFIGURES is illustrative only. Although exemplary embodiments of thepresent inventions have been described in detail in the present patentdocument, a person of ordinary skill in the art will readily appreciatethat equivalents, modifications, variations, etc. of the subject matterof the exemplary embodiments and alternative embodiments are possibleand contemplated as being within the scope of the present inventions;all such subject matter (e.g. modifications, variations, embodiments,combinations, equivalents, etc.) is intended to be included within thescope of the present inventions. It should also be noted thatvarious/other modifications, variations, substitutions, equivalents,changes, omissions, etc. may be made in the configuration and/orarrangement of the exemplary embodiments (e.g. in concept, design,structure, apparatus, form, assembly, construction, means, function,system, process/method, steps, sequence of process/method steps,operation, operating conditions, performance, materials, composition,combination, etc.) without departing from the scope of the presentinventions; all such subject matter (e.g. modifications, variations,embodiments, combinations, equivalents, etc.) is intended to be includedwithin the scope of the present inventions. The scope of the presentinventions is not intended to be limited to the subject matter (e.g.details, structure, functions, materials, acts, steps, sequence, system,result, etc.) described in the specification and/or illustrated in theFIGURES of the present patent document. It is contemplated that theclaims of the present patent document will be construed properly tocover the complete scope of the subject matter of the present inventions(e.g. including any and all such modifications, variations, embodiments,combinations, equivalents, etc.); it is to be understood that theterminology used in the present patent document is for the purpose ofproviding a description of the subject matter of the exemplaryembodiments rather than as a limitation on the scope of the presentinventions.

It is also important to note that according to exemplary embodiments thepresent inventions may comprise conventional technology (e.g. asimplemented and/or integrated in exemplary embodiments, modifications,variations, combinations, equivalents, etc.) or may comprise any otherapplicable technology (present and/or future) with suitability and/orcapability to perform the functions and processes/operations describedin the specification and/or illustrated in the FIGURES. All suchtechnology (e.g. as implemented in embodiments, modifications,variations, combinations, equivalents, etc.) is considered to be withinthe scope of the present inventions of the present patent document.

The invention claimed is:
 1. A brake system configured to be operable byan actuator comprising: (a) a caliper assembly; and (b) a mastercylinder assembly comprising a body; a piston configured to move from aninitial stroke position along a full stroke within the body to actuatebraking action at the caliper assembly; a pushrod configured to engagethe piston; a link actuated by the actuator and configured to engage thepushrod into engagement with the piston; wherein the initial strokeposition of the piston is configured to be set by a feature acting atthe link engaged at the pushrod and configured to determine a distanceof movement by the actuator before braking action is actuated at thecaliper assembly.
 2. The system of claim 1 wherein the caliper assemblycomprises a body configured to provide a series of flow paths tofacilitate maintenance by facilitating flow of fluid within and from thebody; wherein the caliper assembly further comprises plugs to directfluid within and from the body.
 3. The system of claim 1 wherein thecaliper assembly is configured for use of a tool to facilitatemaintenance.
 4. A brake system comprising: a master cylinder assemblycomprising a body; a piston configured to move from an initial strokeposition along a stroke within the body; a pushrod configured to engagethe piston; a link coupled within the body and configured to engage thepushrod; wherein the initial stroke position of the piston is configuredto be set by a feature acting at the link engaged at the pushrod.
 5. Thesystem of claim 4 wherein the feature comprises a threaded end on thepushrod and a bushing on the link; wherein the initial stroke positionof the piston is set by relative position of the threaded end of thepushrod to the bushing on the link.
 6. The system of claim 4 wherein theinitial stroke position of the piston is configured to be adjusted bythe feature.
 7. The system of claim 4 wherein the initial strokeposition of the piston is configured to be set by contact between thefeature and the pushrod; wherein the feature is on the link; and whereinthe initial stroke position of the piston is configured to be set by thefeature on the link as a stop for the pushrod.
 8. The system of claim 4wherein the initial stroke position of the piston is configured to beadjusted by contact between the feature and the pushrod.
 9. The systemof claim 8 wherein the feature is on the link; wherein the feature onthe link is configured to engage the pushrod as a stop; and wherein theinitial stroke position of the piston is configured to be adjusted bythe feature on the link as a stop for the pushrod.
 10. The system ofclaim 4 further comprising an adjuster; wherein the feature is on thepushrod; and wherein the adjuster is configured to be adjusted to engagethe feature on the pushrod to set the initial stroke position of thepiston.
 11. The system of claim 10 wherein the adjuster comprises anadjuster screw; wherein the feature on the pushrod comprises a flange.12. The system of claim 4 further comprising an adjuster; wherein thefeature is on the pushrod; wherein contact by the adjuster comprisescontact with the feature on the pushrod.
 13. The system of claim 12wherein the adjuster is configured to adjust the initial stroke positionof the piston by engagement with the pushrod.
 14. The system of claim 4wherein the initial stroke position of the piston determines a length ofstroke of the piston before braking action at a caliper assembly. 15.The system of claim 4 wherein the stroke of the piston comprises a fullstroke set by contact between the pushrod and the body.
 16. A brakesystem configured to be actuated by an actuator comprising: a mastercylinder assembly comprising a body; a piston configured to move from aninitial stroke position along a stroke within the body; a link actuatedby the actuator and configured to actuate the piston; a mechanismconfigured to adjust an initial position of the actuator; wherein themechanism comprises an adjuster configured to contact the link.
 17. Thesystem of claim 16 wherein the link comprises a pivot link coupledwithin the body.
 18. The system of claim 16 wherein the adjustercomprises a slide having a threaded portion and an unthreaded portion.19. The system of claim 18 wherein the adjuster comprises a detentmechanism.
 20. The system of claim 16 wherein the actuator comprises abrake lever; wherein the mechanism is configured to adjust the initialposition of the brake lever.